- Caterpillar Products
- All Cat Engines
Introduction
| Revision | Summary of Changes in SEBF8146 |
| 32 | Republish due to internal processing error. |
| 31 | Changed verbiage for reusing lifters. |
| 30 | Combined information from SEBF8097, SEBF8104, SEBF8295, SEBF9095, SEBF9101, SEBF9187, SEBF9214, SEBF9215, SEBF9216, and repaired 29 pixelated illustrations. |
© 2019 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.
Information contained in this document is considered Caterpillar: Confidential Yellow.
This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.
For technical questions when using this document, work with your Dealer Technical Communicator (TC).
To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.
Canceled Part Numbers and Replaced Part Numbers
This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.
Important Safety Information
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| Illustration 1 | g02139237 |
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. |
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.
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| Illustration 2 | g00008666 |
This safety alert symbol means:
Pay attention!
Become alert!
Your safety is involved.
The message that appears under the safety alert symbol explains the hazard.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.
The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.
Summary
This guideline applies to all camshafts for Caterpillar engines regardless of bore size. This guideline provides the criteria for inspecting a camshaft. Camshafts that meet the requirement in this guideline can be expected to give normal performance in the same application until the next engine overhaul.
Service Letters and Technical Information Bulletins
| NOTICE |
|---|
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The most recent Service Letters and Technical Information Bulletins that are related to this component shall be reviewed before beginning work. Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired. |
References
| References | |
|---|---|
| Media Number | Title |
| SEBF8042 | Reuse and Salvage"Reuse and Salvage for Crankshafts" |
| SEBF8357 | Reuse and Salvage Guidelines, "General Cleaning Methods" |
| SEHS9031 | "Storage Procedures for Caterpillar Products" |
Tooling and Equipment
| NOTICE |
|---|
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Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools. |
| Required Tooling and Equipment | |
|---|---|
| Part Number | Description |
| Abrasive Sheet (240J Grit) | |
| Abrasive Sheet (600A Grit | |
| Dial Indicator | |
| Indicator Contact Point | |
| Camshaft Support (V-Blocks) | |
| Polishing Stone | |
| Dial Indicator | |
| Dial Indicator Group | |
| Dial Indicator Base | |
| Swivel Post | |
| Eye Loupe | |
| Dial Indicator Gauge Kit | |
| Surface Texture Comparison Gauge | |
| Flashlight | |
| Crack Detection Kit | |
| Lint Free Shop Towels | |
| Profilometer | |
Camshaft Nomenclature
| |
| Illustration 3 | g06205006 |
|
(1) Nose
(2) Ramp (3) Bearing Journal (4) Tapered Lobe (5) Flat Lobe (A) Base Circle (B) Lobe Height (C) Lobe Lift | |
Preliminary Inspection and Cleaning
Immediately after the camshaft has been removed from the engine look for any clear signs of damage that cannot be corrected by reconditioning.
Clean the camshaft with a high-pressure hot washer, solvent, a degreaser or a caustic solution, and rinse. If the method of cleaning does not contain a corrosion or rust inhibitor coat the camshaft with clean engine oil or a rust inhibitor to prevent corrosion or rust. A corrosion or rust inhibitor should be applied within one hour after cleaning.
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Personal injury can result from working with cleaning solvent. Because of the volatile nature of many cleaning solvents, extreme caution must be exercised when using them. If unsure about a particular cleaning fluid, refer to the manufacturer's instructions and directions. Always wear protective clothing and eye protection when working with cleaning solvents. |
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Operating a power washer without proper protective equipment can result in personal injury. Wear the necessary protective equipment before operating a power washer. The necessary projective equipment includes a face shield, protective clothing and rubber gloves. |
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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals. |
| NOTICE |
|---|
|
Keep all parts clean from contaminants Contaminants may cause rapid wear and therefore shorten component life |
Equipment to Inspect and Polish Camshafts
| |
| Illustration 4 | g01430365 |
|
Inspection Equipment | |
| |
| Illustration 5 | g01430389 |
|
Polishing Equipment | |
Tappets or Followers
During normal engine operations, the mating surfaces of each camshaft lobe and tappet or follower establish respective individual wear patterns. If a tappet, or follower is switched to a different location in the engine, the established wear patterns on the camshaft lobes may be incompatible. This could result in premature wear to either the camshaft and/or tappets. Remember the following four items for evaluating the reusability of tappets or followers.
- If a camshaft is used again, make sure that the original tappets or followers are installed in the original locations or replaced with new tappets or followers.
- New tappets or followers and used tappets or followers that have a normal, smooth wear pattern can be installed with a camshaft that is used if the camshaft does not have wear on the camshaft lobe that can be easily seen or felt. Caterpillar recommends installing a replacement camshaft if the tappets or followers or the camshaft has heavy wear.
- Tappets or followers can be reused with original camshaft if in "like new" condition. Used tappets or followers cannot be installed on a new camshaft. Do not use any tappets or followers that operated against damaged camshaft lobes.
- A tappet or follower is wearing normally if the wear surface has a “mirror-like” texture. The dull appearance of the contact surface of the tappet or follower could indicate rapid wear of the tappet or follower and camshaft and the tappet or follower should be replaced.
Camshafts with Lifters
When reusing an original camshaft and lifters, the lifters must be installed in the original location and original orientation. Do not use any lifters that operated against damaged camshaft lobes. Used lifters cannot be installed on a new camshaft. A new camshaft requires the use of new lifters.
Visual Inspection
Examine camshafts only under proper lighting. The best results of inspection can be obtained by rotating the camshaft and moving the camshaft to avoid lighting glare. Poor lighting conditions could cause damage to be missed during visual inspection.
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| Illustration 6 | g06340002 |
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Example of poor lighting Wear on the camshaft can seem less severe under poor lighting conditions. | |
Typical Tappet Wear
| |
| Illustration 7 | g06340013 |
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Example of typical wear. | |
Use Again
| |
| Illustration 8 | g06340014 |
|
An example of typical tappet path wear. | |
Typical Slipper Follower Wear
| |
| Illustration 9 | g01431245 |
|
An example of “mirror-like” finish on lobes. | |
Use Again
| |
| Illustration 10 | g01431296 |
|
Normal wear pattern from slipper followers. | |
Use Again - after polishing
| |
| Illustration 11 | g01431371 |
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Typical wear. | |
Use Again
| |
| Illustration 12 | g01431478 |
|
Typical wear. | |
Use Again - if the lobes have a “mirror-like” finish.
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| Illustration 13 | g01431560 |
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Typical wear. | |
Use Again
| |
| Illustration 14 | g01431584 |
|
Typical wear. | |
Use Again
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| Illustration 15 | g01431601 |
|
Typical wear. | |
Use Again - with the original followers
| |
| Illustration 16 | g01431626 |
|
Typical wear. | |
Use Again - after polishing
| |
| Illustration 17 | g01431638 |
|
Typical wear. | |
Use Again - with the original followers.
Typical Roller Wear
During visual inspection, make sure that every lobe of the camshaft is thoroughly inspected. If one lobe of the camshaft is damaged, the camshaft cannot be reused.
| |
| Illustration 18 | g01265419 |
Normal wear exists on the intake lobe, the exhaust lobe, and the injector lobe.
Use Again
| |
| Illustration 19 | g01265422 |
The normal contact area exists on the intake lobe and the exhaust lobe.
Use Again
| |
| Illustration 20 | g06340203 |
The normal contact area exists on the injector lobe.
Use Again
| |
| Illustration 21 | g01431967 |
|
Typical wear. | |
Use Again
| |
| Illustration 22 | g01431987 |
|
Typical wear. | |
Use Again
| |
| Illustration 23 | g06222564 |
|
(26) Chipped Metal
(27) Deep Grooves from Debris (28) Shallow Grooves from Debris | |
If the chip (26) is outside the pattern of roller contact, then the camshaft can be reused if polished. Remove any metal burrs or raised material. The pattern of roller contact can change if other parts are replaced.
If deep grooves from debris (27) can be seen, the camshaft cannot be reused. If shallow grooves from debris (28) can be seen, the camshaft can be reused after polishing.
| |
| Illustration 24 | g01432183 |
|
Rust Inspect the camshaft with Magnaflux test equipment. Polish the camshaft before inspecting. Use this method to determine if the camshaft is reusable. | |
Corrosive Damage
| |
| Illustration 25 | g06222482 |
|
(6) Stains on the surface
(7) Surface rust (8) Surface pitting | |
Stains on the surface (6) do not affect the reusability of the camshaft. These camshafts can be used again after polishing. See “touch-up” polishing in the "Polishing" section for instructions.
If surface rust or corrosion (7) is on the base circle and covers less than 10% of the total base circle, remove rust with polishing and use again.
If surface pitting (8) cannot be removed by polishing, do not use the camshaft again.
| |
| Illustration 26 | g06222488 |
|
Shallow pitting by rust or corrosion. (9) Shallow pitting on the camshaft lobe. | |
Use Again
Note: Check for discoloration. Use Emery polishing paper to determine the extent of the pitting. Shallow pitting is easily removed. Deep pitting will not be able to be removed.
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| Illustration 27 | g06222491 |
| (10) Deep pitting on the camshaft lobe that has been caused by rust or corrosion. | |
Do Not Use Again - if rust or corrosion pitting cannot be removed by polishing.
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| Illustration 28 | g06340130 |
|
Rust or corrosion pitting with the possibility of rolling contact stress fatigue. | |
Do Not Use Again
Use Magnaflux equipment and use “touch up” polishing with Emery polishing paper before determining the reusability of the camshaft.
Debris Damage
| |
| Illustration 29 | g01430927 |
|
Indentations from debris. | |
Use Again - after polishing
Use the camshaft again after polishing.
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| Illustration 30 | g06222497 |
|
Debris in the tappet path of the camshaft. (11) Debris caused damage to the camshaft lobe. | |
Do Not Use Again
| |
| Illustration 31 | g06222501 |
|
Debris caused damage on the camshaft lobe, but not in the tappet path. (12) Tappet path (13) Debris caused damage. | |
Do Not Use Again
| |
| Illustration 32 | g06222518 |
|
The damaged area of the camshaft lobe cannot be in the tappet path. (14) Debris caused damage in the tappet path. (15) Debris caused damage that is not in the tappet path. | |
Do Not Use Again - if the damage which is caused by debris (14) is in the tappet path.
Use Again - if the damage which is caused by debris (15) is not in the tappet path.
Note: Be sure to check all camshaft lobes for damage which is caused by debris. If any lobe has damage which is caused by debris in the tappet path, replace the camshaft.
| |
| Illustration 33 | g06222527 |
|
The chip (16) from the edge of the camshaft lobe is outside of the wear pattern of the tappet on the camshaft lobe. Use Magnaflux to check for rolling contact stress fatigue. | |
Use Again
Use the camshaft again after polishing. Remove any burrs or raised material from the camshaft lobes. This includes shallow tracking which is caused by debris (18) and deep tracking which is caused by debris (17).
Chips (16) can be the result from misuse or abuse. The camshaft can be used again if the chip is outside the contact surface of the tappet.
Note: The contact surface area or wear patterns of the tappet can change when other parts are replaced.
Deep tracking (17) must be polished. If deep tracking cannot be removed by “touch up” polishing withEmerypolishing paper do not use the camshaft.
Reuse the camshaft if the shallow tracking (18) can be removed by polishing.
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| Illustration 34 | g06340184 |
|
Light tracking which is caused by debris in tappet path | |
Use Again - if tracking which is caused by debris can be removed by “touch up” polishing with Emery polishing paper.
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| Illustration 35 | g06340187 |
|
Light tracking which is caused by debris in tappet path. Using good lighting is essential to visual inspection. | |
Use Again
Note: If tracking which is caused by debris is present on one lobe most likely other camshaft lobes will also contain tracking.
Pitting
| |
| Illustration 36 | g06222552 |
| (24) Surface Pitting | |
Do Not Use Again - if surface pitting (24) cannot be removed by polishing.
| |
| Illustration 37 | g06222554 |
| (24) Surface Pitting | |
Do Not Use Again - if surface pitting (24) cannot be removed by polishing.
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| Illustration 38 | g06222560 |
| (25) Chipped Metal | |
Do Not Use Again
| |
| Illustration 39 | g06222566 |
|
Initial signs of pitting are caused by fatigue from loading on the edges. (32) Pitting | |
Do Not Use Again
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| Illustration 40 | g06222568 |
|
Initial signs of pitting are caused by fatigue from loading on the edges. (32) Pitting | |
Do Not Use Again
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| Illustration 41 | g06222569 |
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Initial signs of pitting are caused by fatigue from loading on the edges. (32) Pitting | |
Do Not Use Again
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| Illustration 42 | g06222948 |
|
Pitting from fatigue | |
Do Not Use Again
| |
| Illustration 43 | g06340202 |
Micro-pitting
Light micro-pitting can be caused by fuel or coolant in the engine oil.
Note: Investigate the causes or sources of fuel or coolant in the engine oil and correct the causes or sources of fuel or coolant in the engine oil.
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| Illustration 44 | g06340189 |
|
Smear marks and micro-pitting in the tappet path. (19) Micro-pitting. (20) Smear marks. | |
Use Again - after polishing.
Do Not Use Again - if micro-pitting cannot be removed by “touch up” polishing.
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| Illustration 45 | g06340190 |
|
Shallow micro-pitting in the tappet path. | |
Use Again - if micro-pitting can be removed by polishing.
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| Illustration 46 | g06340192 |
|
Deep micro-pitting in the tappet path. | |
Do Not Use Again - if micro-pitting cannot be removed by polishing.
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| Illustration 47 | g06340193 |
|
Deep micro-pitting in the tappet path. | |
Do Not Use Again - if micro-pitting cannot be removed by polishing.
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| Illustration 48 | g06340195 |
|
Micro-pitting in the tappet path. | |
Use Again - if micro-pitting can be removed by “touch up” polishing.
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| Illustration 49 | g06340197 |
|
Shallow micro-pitting in the tappet path. | |
Use Again - if micro-pitting can be removed by polishing.
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| Illustration 50 | g06340200 |
|
Micro-pitting in the path for the tappet | |
Use Again - if micro-pitting can be removed by polishing.
Do not reuse camshafts that show signs of micro-pitting. Deep micro-pitting is unacceptable in any camshaft. The camshaft should be replaced if micro-pitting exists.
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| Illustration 51 | g01265404 |
Deep micro-pitting exists on the intake lobe or the exhaust lobe.
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| Illustration 52 | g01265407 |
Severe micro-pitting exists on the intake lobe or the exhaust lobe.
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| Illustration 53 | g01265409 |
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| Illustration 54 | g01265416 |
Deep micro-pitting exists on the injector lobe.
Fatigue Pitting
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| Illustration 55 | g06340208 |
|
Fatigue pitting from edge loading of the tappet. (21) Indications of fatigue pitting. | |
Do Not Use Again - if micro-pitting cannot be removed by “touch up” polishing.
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| Illustration 56 | g06340210 |
|
Initial fatigue pitting from edge loading | |
Do Not Use Again - if pitting cannot be removed by polishing.
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| Illustration 57 | g06340212 |
|
Initial fatigue pitting from edge loading | |
Do Not Use Again - if pitting cannot be removed by polishing.
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| Illustration 58 | g06340213 |
|
Fatigue pitting from edge loading. | |
Do Not Use Again - if pitting cannot be removed by polishing.
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| Illustration 59 | g06340217 |
|
Severe fatigue pitting | |
Rolling Contact Stress Fatigue
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| Illustration 60 | g01432440 |
|
Crushing in pattern of roller | |
Do Not Use Again
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| Illustration 61 | g01432470 |
Do Not Use Again
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| Illustration 62 | g01432491 |
Do Not Use Again
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| Illustration 63 | g01432509 |
Do Not Use Again
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| Illustration 64 | g06340220 |
Welded Lobes
Caterpillar does not recommend using any camshafts with welded lobes. Caterpillar does not endorse welding of cast camshafts.
| |
| Illustration 65 | g01431817 |
Do Not Use Again
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| Illustration 66 | g01431829 |
Do Not Use Again
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| Illustration 67 | g01431838 |
Camshaft Magnetic Particle Inspection
Note: The camshaft must be cleaned thoroughly prior to beginning any inspection work. Dirty camshafts can contaminate the solution and mask indications. Be careful not to damage the camshaft with improper and abrasive cleaning, even a small amount of damage may mask indications.
Some camshafts can have fissures or cracks in the flange area. Therefore, inspect the flange area visually and then with the magnetic particle method to reveal any cracks or weakness. If cracks or fissures can be seen without magnification or magnetic particle inspection, the camshaft cannot be reused. Also, if any cracks or fissures in the flange area are revealed during the Magnetic Particle Inspection, the camshaft cannot be reused.
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| Illustration 68 | g03342709 |
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| Illustration 69 | g03342777 |
|
If there is a crack in the flange area of the camshaft, do not reuse the camshaft. | |
Note: Refer to Reuse and Salvage Guideline, SEBF8042, "Resue and Salvage for Crankshafts" for additional information on how to perform a Magnetic Particle Inspection.
Measuring the Straightness of the Camshaft
Every camshaft must be checked for maximum allowable runout for the journal. The maximum allowable runout for the journal is
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| Illustration 70 | g06222962 |
|
Measurements that are used to determine the straightness of the camshaft (D) Length of single segment (E) Length of half of the camshaft | |
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| Illustration 71 | g06340222 |
| |
| Illustration 72 | g06340224 |
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| Illustration 73 | g06340225 |
Multiply dimension (D) or dimension (E) by the maximum allowable runout for the journal. The result is the total allowable indicator reading.
Procedure to Check the Straightness of the Camshaft
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| Illustration 74 | g01545633 |
|
Camshaft that is resting on two vee blocks that are for support | |
| |
| Illustration 75 | g01545973 |
|
Measuring runout of the camshaft | |
Place the vee blocks that are for support under the first bearing journal and the last bearing journal. Ensure that the camshaft and vee blocks are stationary. Use the 8T-5096 Dial Indicator to measure runout.
Lubricate the camshaft bearing journals and install the camshaft into the engine block. Use a torque wrench on the rear end of the camshaft and check the amount of initial torque that is required to rotate the camshaft inside the camshaft bearings.
Polishing
After cleaning the camshaft, visually inspect each camshaft journal and each camshaft lobe for damage.
Polishing camshafts makes use of identical procedures, materials, and required equipment as polishing crankshafts. Refer to Reuse and Salvage Guidelines, SEBF8042, "Reuse and Salvage for Crankshafts" for polishing instructions.
Any camshaft lobes with corrosive damage (rust), minor damage from debris (indentations), and fatigue pitting need to be polished before determining reusability. Follow the procedures below to polish a camshaft lobe with “touch-up” polishing.
- Polish the camshaft lobe with Emery polishing paper. 1U-6858 Abrasive Material (200 grit or less) should be used. This part of the procedure is the “rough polishing” of the camshaft lobes.
- Polish the camshaft lobe with Emery polishing paper 1U-8283 (600 grit or less) should be used. This part of the procedure is the “fine polishing” of the camshaft lobes.
- Wash the camshaft or clean the camshaft after polishing to remove any excess grit or debris from polishing.
| NOTICE |
|---|
|
Keep all parts clean from contaminants Contaminants may cause rapid wear and shorten component life |
Procedure to Measure the Surface Texture of the Camshaft
The maximum permissible surface texture for camshaft lobes and bearing journals is listed below in Table 4. The surface texture of the camshaft lobes and bearing journals can be checked with a profilometer that measures the surface or roughness.
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| Illustration 76 | g01546195 |
|
Measuring the surface texture or roughness of the camshaft lobe | |
| |
| Illustration 77 | g01546399 |
|
Measuring the surface texture or roughness of the camshaft bearing journal | |
A profilometer must meet certain criteria.
- The profilometer must have a power drive that will strike the lobe or the bearing automatically.
- The radius of the stylus must be approximately
0.013 mm (0.0005 inch) . - The profilometer should have a cutoff length of
0.80 mm (0.032 inch) .
Surface Texture Specifications
| Required Surface Texture Specification | |||||
|---|---|---|---|---|---|
| Part Number | Max Journal Surface Texture | Max Lobe Surface Texture | Part Number | Max Journal Surface Texture | Max Lobe Surface Texture |
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N/A | |
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N/A | ||
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Storage Procedures
Proper protection of the camshaft from corrosion is important. Corrosion will start in as little as one hour after the camshaft has been cleaned.
When the camshaft will not be inspected for one hour or less the camshaft should be coated with a rust or corrosion inhibitor or coated with clean engine oil. The camshaft should be individually wrapped to prevent contamination, and should be stored in a protected area to avoid damage. See Illustration 78.
When the camshaft will not be inspected in two days or more the camshaft should be coated with a rust or corrosion inhibitor or coated with clean engine oil and should be placed in a container which is clean and structurally solid. The container should be covered or wrapped in plastic to prevent damage and contamination to the camshaft. See Illustration 79.
Refer to SEHS9031Special Instruction, "Storage Procedure for Caterpillar Products" for more information.
| |
| Illustration 78 | g06278538 |
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Example of protection for a component that is stored for a shorter term | |
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| Illustration 79 | g06278539 |
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Example of protection for a component that is stored for a longer period | |